Product metering system

ABSTRACT

A product metering system for accurately dispensing one or more products. The product metering system generally includes a vehicle wash product supply fluidly connected to an electronic control valve and a control unit in communication with the electronic control valve. The electronic control valve operates at an open/close ratio that dispenses the product supply at a desired flow rate.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.13/011,493 filed on Jan. 21, 2011, which is a continuation-in-part ofU.S. application Ser. No. 12/203,510 filed Sep. 3, 2008. Each of theaforementioned patent applications, and any applications relatedthereto, is herein incorporated by reference in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable to this application.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally to product dispensers forvehicle washes and more specifically it relates to a product meteringsystem for dispensing one or more products in an efficient manner.

Description of the Related Art

Any discussion of the related art throughout the specification should inno way be considered as an admission that such related art is widelyknown or forms part of common general knowledge in the field.

Vehicle washes are comprised of various types of facilities capable ofwashing various types of vehicles (e.g. cars, trucks, planes, trains)such as but not limited to self-service manual vehicle washes, in-bayautomatic vehicle washes, and tunnel vehicle washes. Vehicle washesdispense various types of products including but not limited to water,detergent, protective coatings (e.g. wax, polish), tire dressing,coloring, spot free rinse and the like.

A vehicle wash needs to accurately control the amount of productdispensed to ensure a quality wash of a vehicle and to avoid wastingcostly products. Vehicle washes currently utilize various orifice sizesto meter a product (e.g. detergent, spot free rinse) into a flow ofwater. One problem with utilizing orifices to meter products is thatthey can become partially or fully blocked thereby undesirably modifyingthe product dispensing ratio. Another problem with utilizing orificeswithin a vehicle wash is that if the mix ratio of two products isdesired, the orifices have to be replaced which is time consuming,expensive and prone to human error. Another problem with utilizingorifices within the vehicle wash is the orifice is in the product flowthereby contact with the product being metered is unavoidable whendisassembling.

Because of the inherent problems with the related art, there is a needfor a new and improved product metering system for effectively combiningtwo products within a vehicle wash.

BRIEF SUMMARY OF THE INVENTION

The general purpose of the present invention is to provide a productmetering system that has many of the advantages of the vehicle washproduct dispensers mentioned heretofore. The invention generally relatesto a product dispenser which includes a vehicle wash product supplyfluidly connected to an electronic control valve and a control unit incommunication with the electronic control valve. The electronic controlvalve operates at an open/close ratio that dispenses the product supplyat a desired flow rate.

There has thus been outlined, rather broadly, some of the features ofthe invention in order that the detailed description thereof may bebetter understood, and in order that the present contribution to the artmay be better appreciated. There are additional features of theinvention that will be described hereinafter and that will form thesubject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction or to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of the description and should not beregarded as limiting.

An object is to provide a product metering system for effectivelycombining two products within a vehicle wash.

Another object is to provide a product metering system that is capableof combining various types of products such as but not limited to liquid(e.g. detergents, water, coloring, wax) and powder.

An additional object is to provide a product metering system thatensures a desired proportion of two or more products.

A further object is to provide a product metering system that providesadjustable product ratios.

Another object is to provide a product metering system that preciselymeters a product flow.

Another object is to provide a product metering system that is capableof supplying precise amounts of product into systems requiring eitherpressure or a vacuum.

Another object is to provide a product metering system that maintains aconsistent product ratio and does not become blocked.

Another object is to provide a product metering system that may beutilized to produce various colors within a vehicle wash.

Another object is to provide a product metering system that may beutilized to produce various scents within a vehicle wash.

A further object is to provide a product metering system that is capableof accurately dispensing one or more products in an efficient manner.

Other objects and advantages of the present invention will becomeobvious to the reader and it is intended that these objects andadvantages are within the scope of the present invention. To theaccomplishment of the above and related objects, this invention may beembodied in the form illustrated in the accompanying drawings, attentionbeing called to the fact, however, that the drawings are illustrativeonly, and that changes may be made in the specific constructionillustrated and described within the scope of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Various other objects, features and attendant advantages of the presentinvention will become fully appreciated as the same becomes betterunderstood when considered in conjunction with the accompanyingdrawings, in which like reference characters designate the same orsimilar parts throughout the several views, and wherein:

FIG. 1 is a front view of a vehicle wash dispensing product on avehicle.

FIG. 2 is a block diagram illustrating the present invention.

FIG. 3 is a block diagram illustrating the present invention using aninductor and foam generator.

FIG. 4 is a block diagram illustrating the present invention using areconstituting device.

FIG. 5 is a block diagram illustrating an exemplary control system forthe present invention.

FIG. 6 is a flowchart illustrating the overall operation of the presentinvention.

FIG. 7a is a chart illustrating a first open/close ratio for anelectronic control valve.

FIG. 7b is a chart illustrating a second open/close ratio for anelectronic control valve.

FIG. 8 is a chart illustrating an alternative embodiment utilizing pulsewidth modulation.

DETAILED DESCRIPTION OF THE INVENTION A. Overview

Turning now descriptively to the drawings, in which similar referencecharacters denote similar elements throughout the several views, FIGS. 1through 8 illustrate a product metering system 10, which comprises avehicle wash product supply fluidly connected to an electronic controlvalve and a control unit in communication with the electronic controlvalve. The electronic control valve operates at an open/close ratio thatdispenses the product supply at a desired flow rate.

B. Vehicle Wash

The present invention may be utilized with various types of vehiclewashes. Vehicle washes are comprised of various types of facilitiescapable of washing various types of vehicles (e.g. cars, trucks, planes,trains). FIG. 1 illustrates an exemplary vehicle wash comprised of an“in-bay” vehicle wash system. It can be appreciated that the vehiclewash may be comprised of various other types of vehicle washes includingautomatic tunnel vehicle washes and self-service manual vehicle washes.

The vehicle wash has at least a first product supply 20 comprised of aliquid, a powder, particulate material, a gas, a fluid or the like. Thefirst product supply 20 is preferably metered into a flow of water priorto being dispensed by the product dispenser 76. The first product supply20 may be comprised of any product used in a vehicle wash including butnot limited to water, cleaning products (e.g. detergent), scentedproduct, protective products (e.g. wax, sealant), tire dressing,coloring product, spot free rinse and the like. As shown in FIG. 1 ofthe drawings, the first product supply 20 is applied to the vehiclewithin the vehicle wash via the product dispenser 76 (e.g. nozzle).

As shown in FIGS. 2 through 4 of the drawings, a second product supply22 may be utilized within the present invention and combined with thefirst product supply 20. The second product supply 22 is metered to adesired flow rate into the first product supply 20 as determined by themaster control unit 50.

C. Electronic Control Valves

The present invention preferably utilizes electronic control valves tooperating in a pulsing manner to deliver one or more products at acontrolled flow rate. It is preferable that the electronic controlvalves be comprised of solenoid valves capable of operating at variouspulse rates, however other types of valves may be utilized.

FIGS. 2 through 5 of the drawings illustrate a first electronic controlvalve 40 fluidly connected to the first product supply 20. A first pump30 may be fluidly positioned between the first product supply 20 and thefirst electronic control valve 40 to provide the first product supply 20in a pressurized manner. The first electronic control valve 40 iscomprised of any valve capable of operating at a first open/close ratiothat dispenses the first product supply 20 at a desired first flow rate.The first open/close ratio preferably produces a consistent flow rate ofthe first product supply 20 to ensure that the end product dispensed bythe product dispenser 76 onto the vehicle has the proper ratios ofproduct.

FIGS. 2 through 5 of the drawings also illustrate a second electroniccontrol valve 42 fluidly connected to the second product supply 22. Asecond pump 32 may be fluidly positioned between the second productsupply 22 and the second electronic control valve 42 to provide thesecond product supply 22 in a pressurized manner. The second electroniccontrol valve 42 is comprised of any valve capable of operating at asecond open/close ratio that dispenses the second product supply 22 at adesired second flow rate that has a desired ratio with respect to thefirst flow rate. The second open/close ratio preferably produces aconsistent flow rate of the second product supply 22 to ensure that theend product dispensed by the product dispenser 76 onto the vehicle hasthe proper ratios of product. As can be appreciated, more than twoproduct supplies metered by a corresponding number of electronic controlvalves may be utilized within the present invention and the illustrationin the figures of two electronic control valves is merely forillustration purposes of a preferred embodiment of the presentinvention. In addition, a single first electronic control valve 40 maybe utilized to control a single first product supply 20 within thevehicle wash.

FIGS. 7a and 7b of the drawings illustrate an exemplary open/close ratiothat may be used with the electronic control valves. The firstopen/close ratio and the second open/close ratio may be different or thesame depending upon the desired end product ratio. The open/close ratiosmay be comprised of any ratio that produces the desired flow rate ofproduct to the vehicle wash and that the electronic control valve iscapable of being operated at.

D. Control Unit

FIGS. 2 through 5 illustrate a first control unit 52 in communicationwith the first electronic control valve 40 and a second control unit 54in communication with the second electronic control valve 42. A mastercontrol unit 50 is preferably in communication with the first controlunit 52 and the second control unit 54 or the master control unit 50 maybe in direct communication with the electronic control valves 40, 42.The control units 50, 52, 54 are preferably programmable to allow theuser to adjust the open/close ratios of the electronic control valves40, 42. The control units 50, 52, 54 may be comprised of any electronicdevice capable of performing calculations, storing data, receiving dataand/or transmitting data.

One or more sensors 56 are preferably in communication with one or moreof the control units 50, 52, 54. The sensor 56 detects a condition ofthe vehicle wash such as but not limited to the end product flow ratebeing dispensed from the product dispenser 76, temperature, humidity andthe like.

E. Fluid Delivery System

FIGS. 2 through 4 of the drawings illustrate exemplary fluid deliverysystems utilizing a first product supply 20 and a second product supply22. As illustrated in FIGS. 2 through 4 of the drawings, a first line 60is fluidly connected to the first electronic control valve 40 and asecond line 62 is fluidly connected to the second electronic controlvalve 42 to transfer the metered first product supply 20 and secondproduct supply 22 respectively. The first line 60 and the second line 62are both fluidly connected to a combined line 64 that combines theproduct supplies 20, 22 and transfers the same to the product dispenser76 as shown in FIG. 2 of the drawings. The product dispenser 76 may becomprised of any dispensing device capable of dispensing the productsonto a vehicle within the vehicle wash (e.g. spray nozzle). Ifadditional product supplies are utilized, additional lines would beadded and joined into the combined line 64.

FIG. 3 illustrates a variation of the present invention wherein aninductor 70 is fluidly connected to the combined line 64. In addition, awater supply 12 is fluidly connected to the inductor 70 to provide asupply of water to the inductor 70. The inductor 70 is fluidly connectedto a foam generator 72 that generates foam from the water and meteredproducts. The foam is transferred to the product dispenser 76 fordispensing upon the vehicle in the vehicle wash.

FIG. 4 illustrates another variation of the present invention wherein aflow meter 44 is fluidly connected between a water supply 12 and areconstituting device 74. The combined line 64 is fluidly connected tothe reconstituting device 74 and the reconstituted fluid is delivered tothe product dispenser 76. As further shown in FIG. 4 of the drawings,the control units 52, 54 are preferably in communication with the flowmeter 44 to ensure a proper ratio of dispensed products into thereconstituting device 74 with respect to the water being supplied.

G. Operation of Preferred Embodiment

FIG. 6 provides a flowchart illustrating the overall operation of thepresent invention. In particular, the first pump 30 is activated(additional pumps are activated if present). The desired first flow ratefor the first product supply 20 is determined either by a preprogrammedflow rate or a flow rate calculated by the first control unit 52. Thefirst control unit 52 determines the open/close ratio needed to producethe desired first flow rate. The open/close ratio is calculatedutilizing the pressure and flow rate of the first pump 30, the size ofthe first electronic control valve 40 and other factors relevant tocalculating the first flow rate. The first electronic control valve 40is thereafter activated according to the determined open/close ration.FIGS. 7a and 7b illustrate an exemplary open/close ratio for the firstelectronic control valve 40 wherein FIG. 7a illustrates a significantlylower flow rate than the flow rate of FIG. 7b . In FIG. 7a , the firstelectronic control valve 40 is only open 250 MS and is closed 750 MS. InFIG. 7b , the first electronic control valve 40 is open 500 MS and isonly closed 500 MS. Various other open/close ratios may be utilized. Inaddition, the open/close ratio used for the first control valve may bestatic or dynamic dependent upon real-time factors (e.g. a change inpump pressure, a change in the amount of water being supplied, etc.).

The present invention is not limited to dispensing only one firstproduct supply 20 (with or without water). The present invention may beutilized to meter and dispense two or more products as discussedpreviously utilizing a corresponding number of electronic controlvalves. For example, the present invention may utilize three coloredproduct supplies comprised of three primary colored products to providean infinite amount of colored products to the vehicle wash (e.g. coloredwax). In addition, the present invention may utilize two or more scentedproduct supplies to provide various scented outputs to the vehicle wash.

H. Operation of Alternative Embodiment

FIG. 8 illustrates an alternative embodiment that reduces the electricalpower consumed by the electronic control valve 40, 42. There are twomain sections illustrated in FIG. 8: the upper portion illustrates thepulse width modulation utilized to meter a desired product flow ratethrough the electronic control valve 40, 42; the lower portionillustrates the state of the valve as being on or off to dispense theproduct. The alternative embodiment allows for a smaller solenoid to beused because the coil does not need to be as large thereby reducingelectrical power used, reducing the overall physical size and reducingthe cost of the electronic control valve 40, 42. The reduction in sizeof the solenoid coil is in-part because less heat is required to bedissipated when using the alternative embodiment as discussed below.

The lower portion of the chart in FIG. 8 illustrates the desired on oroff flow of a desired product through the electronic control valve 40,42. As shown in FIG. 8, the initial state is in the OFF state indicatingthat no electrical power is transmitted to the electronic control valve40, 42 and therefore no product flows through the electronic controlvalve 40, 42.

When product is desired to be delivered through the electronic controlvalve 40, 42, the state is changed to ON as shown by the lower portionof the chart in FIG. 8. When the state is initially changed to ON todeliver a desired product through the electronic control valve 40, 42,the control unit 52, 54 transmits a “Hit Power” which is a constantvoltage applied to the valve coil of the electronic control valve 40, 42to ensure that the electronic control valve 40, 42 is fully opened andin an open state. It has been found that a constant voltage ispreferable to open the electronic control valve 40, 42 initially fromthe closed state and after the electronic control valve 40, 42 is openedthen a pulse width modulated (PWM) power may be applied to maintain theelectronic control valve 40, 42 in the open state as further shown inFIG. 8 of the drawings. The Hit Power is generally comprised of a highpower and is preferably a constant voltage.

As an example of the alternative embodiment shown in FIG. 8 of thedrawings, it has been found that a “Hit Power” period set for 15 msprovides sufficient power and time to fully open the electronic controlvalve 40, 42. It can be appreciated the various other periods of HitPower may be applied depending upon various factors such as the solenoidcoil size and the valve.

After 15 ms, the Hit Power applied to the electronic control valve 40,42 is reduced to the PWM power thereby reducing the overall powerconsumed by the valve coil of the electronic control valve 40, 42. Thelength of time that the PWM power is applied depends upon the desiredproduct flow rate along with the “valve off” time. After a specifiedperiod time such as 85 ms as illustrated by the “PWM Power” row, the PWMpower is terminated and electrical power supplied to the electroniccontrol valve 40, 42 is terminated for a period of time (e.g. 900 ms) asillustrated by the “Valve Off” row. After the Valve Off period hasexpired, the Hit Power is applied again for a period of time (e.g. 15ms) followed by the PWM Power for another period of time (e.g. 85 ms) asillustrated previously. The process continues until the desired amountof product has been dispensed through the electronic control valve 40,42 and then the valve control is set to OFF thereby closing theelectronic control valve 40, 42 into a closed state.

The PWM Power is preferably comprised of the same voltage used for theHit Power, but is cycled on and off at a high frequency which is at arate higher than the control valve can change state. The PWM Power ispreferably comprised of a high frequency voltage that is adjustabledepending upon the electronic control valve 40, 42 and the environmentalconditions. As an example, an exemplary frequency for the PWM Power isapproximately 5 kHz.

What has been described and illustrated herein is a preferred embodimentof the invention along with some of its variations. The terms,descriptions and figures used herein are set forth by way ofillustration only and are not meant as limitations. Those skilled in theart will recognize that many variations are possible within the spiritand scope of the invention, which is intended to be defined by thefollowing claims (and their equivalents) in which all terms are meant intheir broadest reasonable sense unless otherwise indicated. Any headingsutilized within the description are for convenience only and have nolegal or limiting effect.

What is claimed is:
 1. A method of operating a vehicle wash, comprising:positioning a vehicle within a vehicle wash, wherein the vehicle wash iscomprised of: a first pump fluidly connected to a product supply,wherein the product supply is comprised of a liquid; an electroniccontrol valve fluidly connected to the first pump, wherein theelectronic control valve operates at an open/close ratio that dispensesthe product supply at a flow rate, wherein the open/close ratio iscomprised of an on state for an on period of time and an off state foran off period of time, and wherein the open/close ratio produces aconsistent flow rate of the product supply; a nozzle fluidly connectedto the electronic control valve to dispense the product supply to thevehicle; and a control unit in communication with the electronic controlvalve, the control unit programmed to control the open/close ratio,wherein the control unit calculates the open/close ratio needed toproduce the flow rate of the product supply utilizing a pressure of theproduct supply from the first pump; calculating by the control unit theopen/close ratio needed to produce the flow rate of the product supplyutilizing the pressure of the product supply from the first pump;operating the electronic control valve at the open/close ratio toproduce the consistent flow rate of the product supply; and dispensingthe product supply by the nozzle to the vehicle at the flow rate.
 2. Amethod of operating a vehicle wash, comprising: positioning a vehiclewithin a vehicle wash, wherein the vehicle wash is comprised of: a firstpump fluidly connected to a first product supply and a second pumpfluidly connected to a second product supply, wherein the first productsupply is comprised of a liquid and wherein the second product supply iscomprised of a liquid; an first electronic control valve fluidlyconnected to the first pump, wherein the first electronic control valveoperates at a first open/close ratio that dispenses the first productsupply at a first flow rate, wherein the first open/close ratio iscomprised of an on state for an on period of time and an off state foran off period of time, and wherein the first open/close ratio produces aconsistent first flow rate of the first product supply; a secondelectronic control valve fluidly connected to the second pump, whereinthe second electronic control valve operates at a second open/closeratio that dispenses the second product supply at a second flow rate,wherein the second open/close ratio is comprised of an on state for anon period of time and an off state for an off period of time, andwherein the second open/close ratio produces a consistent second flowrate of the first product supply; a nozzle fluidly connected to thefirst electronic control valve and the second electronic control valveto dispense the first product supply and the second product supply tothe vehicle; and a control unit in communication with the firstelectronic control valve and the second electronic control valve, thecontrol unit is programmed to control the first open/close ratio and thesecond open/close ratio, wherein the control unit calculates the firstopen/close ratio needed to produce the first flow rate of the firstproduct supply utilizing a pressure of the first product supply from thefirst pump, and wherein the control unit calculates the secondopen/close ratio needed to produce the second flow rate of the secondproduct supply utilizing a pressure of the second product supply fromthe second pump; calculating by the control unit the first open/closeratio needed to produce the first flow rate of the first product supplyutilizing the pressure of the first product supply from the first pump;calculating by the control unit the second open/close ratio needed toproduce the second flow rate of the second product supply utilizing thepressure of the second product supply from the second pump; operatingthe first electronic control valve at the first open/close ratio toproduce the consistent first flow rate of the first product supply;operating the second electronic control valve at the second open/closeratio to produce the consistent second flow rate of the second productsupply; combining the first product supply and the second product supplyfrom the first electronic control valve and the second electroniccontrol valve into a combined product supply; and dispensing thecombined product supply by the nozzle to the vehicle.